1. Objective Determination of Minimum
Engine M
E i Mapping Requirements for
i R i t f
Optimal SI DIVCP Engine Calibration
Pete Maloney
The MathWorks, Inc.
,

2. Topics
Problem Definition
Results Summary
y
Problem Solving Approach
Problem-Solving
Conclusions and Next Steps
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3. Problem Definition
Determine Minimum Number of Spark-Sweep
Test-Points Required For Optimal Calibration
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4. Results Summary
Torque Residuals as a function of DoE Size
3
2
1
0
duals (Nm)
-1
Torque Resid
-2 Median
M di
Max
Min
-3
-4
-5
-6
-7
50 100 150 200 250 300 350 400 450
Number of DoE Points
•Approximately 100 Spark-Sweeps Required to Optimally Calibrate This
Type of Engine With a Workload Feasible 2 Stage Modeling Approach
Workload-Feasible 2-Stage
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5. Problem-Solving Approach
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6. Problem-Solving Approach
52 Pt. Sobol Survey Test Design
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7. Problem-Solving Approach
5th Sobol Augmentation Design
(406 Pts)
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8. Problem-Solving Approach
2-Stage Model Definition
Local Model Global Model
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9. Problem-Solving Approach
Optimal Calibrations From 52 Pt. Survey DoE
p y
Optimal Calibrations From Final Augmentation: 406 Pt. DoE 5
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10. Problem-Solving Approach
Exhaustive Calibration Development DoE
100 Cam-Phaser
Combinations at Each
of 100 Calibration Table
Breakpoints in Speed/Load
(10,000
(10 000 Spark Sweeps)
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11. Problem-Solving Approach
Optimal Calibrations From Exhaustive DoE
p
Optimal Calibrations From Final Augmentation: 406 Pt. DoE 5
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12. Problem-Solving Approach
DoE Augmentation 5 Calibration vs Baseline Exhaustive Calibration
g
Spark Advance Residuals (DegBTDC) Intake Phaser Advance Residuals (DegCrank) Exhaust Phaser Retard Residuals (DegCrank)
0.9 10 0.9 10 0.9 10
8 8 8
0.8 0.8 0.8
6 6 6
0.7 0.7 0.7
4 4 4
0.6 0.6 0.6
2 2 2
%)
%)
Load (% )
Load (%
Load (%
0.5 0 0.5 0 0.5 0
-2 -2 -2
0.4 0.4 0.4
-4 -4 -4
0.3 0.3 0.3
-6 -6 -6
0.2 0.2 0.2
-8 -8 -8
0.1
01 -10
10 0.1
01 -10
10 0.1
01 -10
10
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Speed (RPM) Speed (RPM) Speed (RPM)
Torque Residuals (Nm) Residual Fraction Residuals (%) Torque Prediction Error (Nm)
0.9 2 0.9 5 0.9 10
1 4.5
45 8
0.8 0.8 0.8
0 4 6
0.7 0.7 0.7
-1 3.5 4
0.6 0.6 0.6
-2 3 2
Load (%)
Load (%)
Load (%)
0.5 -3 0.5 2.5 0.5 0
-4 2 -2
0.4 0.4 0.4
04
-5 1.5 -4
0.3 0.3 0.3
-6 1 -6
0.2 0.2 0.2
-7 0.5 -8
0.1 -8 0.1 0 0.1 -10
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Speed (RPM) Speed (RPM) Speed (RPM)
•Engine Model Re-Tested At DoE 5 and Exhaustive Calibraiton Table Breakpoints
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13. Conclusions And Next Steps
•~100 Spark Sweeps Required For DIVCP Calibration
•VCP Calibration Shapes Can Vary But Yield Similar Results
•VCP Calibration Shapes Sensitive to Modeling Process
•Sparser Version of Exhaustive Process Should Be Tried
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